Packaging system for a component including a compressive and shock-absorbent packing insert

ABSTRACT

A packaging system for a component is disclosed. The packaging system comprises a box and a compressible and shock-absorbent packing insert. The packing insert is placed in the box after nesting a component within the insert. The insert comprises a main panel, a first end tube hingedly coupled to the main panel, a second end tube hingedly coupled to the main panel opposite the first end tube, a first side tube hingedly coupled to the main panel, the first side tube being adjacent to the first end tube and a second side tube hingedly coupled to the main panel, the second side tube being adjacent to the second end tube and opposite the first side tube wherein the first and second side tube panels and the first and second side tube panels may include at one or more cutouts to enhance the flexing capability of the packing insert. Accordingly, the packing insert in accordance with the present invention employs low cost, environment friendly material to protect fragile components from any potential damage that can be caused during the shipping process.

FIELD OF THE INVENTION

[0001] The present invention relates to tube/box inserts and morespecifically to a packing insert to be used with shock-sensitive harddisk drives or similar components of varying sizes.

BACKGROUND OF THE INVENTION

[0002] Previous approaches to shipping fragile components (i.e., harddrives) have typically utilized substances such as resilient foam, aswell as adhesives and other non-recyclable materials when packaging suchcomponents.

[0003] For an example of a typical packaging system, please refer now toFIG. 1. FIG. 1 is an exploded view of a typical packaging system forfragile components such as a hard drive. This approach utilizes apolyurethane bottom cushion 12, a polyurethane middle cushion 14, apolyurethane top cushion 16 and a corrugated tray 18, all of which fitinto a corrugated carton 10. Utilizing this approach, the component tobe shipped (not shown) is inserted between the polyurethane top cushion16 and the polyurethane bottom cushion 12, through the polyurethanemiddle cushion 14. However, as previously mentioned, a drawback to thisapproach is the high cost of the polyurethane material, as well as thefact that polyurethane is not biodegradable and thus not environmentfriendly.

[0004] Accordingly, what is needed is a system and method which makesuse of lower cost, environmentally safe and recyclable materials and yetsafely protects fragile components from any potential damage that can becaused during the shipping process. The present invention addresses sucha need.

SUMMARY OF THE INVENTION

[0005] A packaging system for a component is disclosed. The packagingsystem comprises a box and a compressible and shock-absorbent packinginsert. The packing insert is placed in the box after nesting acomponent within the insert. The insert comprises a main panel, a firstend tube hingedly coupled to the main panel, a second end tube hingedlycoupled to the main panel opposite the first end tube, a first side tubehingedly coupled to the main panel, the first side tube being adjacentto the first end tube and a second side tube hingedly coupled to themain panel, the second side tube being adjacent to the second end tubeand opposite the first side tube wherein the first and second side tubepanels and the first and second side tube panels include at least onecutout to enhance the flexing capability of the packing insert.

[0006] Accordingly, the packing insert in accordance with the presentinvention employs low cost, environment friendly material to protectfragile components from any potential damage that can be caused duringthe shipping process.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]FIG. 1 is an exploded view of a conventional packaging system forfragile components.

[0008]FIG. 2 is an exploded view of a packaging system in accordancewith the present invention.

[0009]FIG. 3 shows the assembled packing insert in accordance with thepresent invention.

[0010]FIG. 4 is an illustration of the packing insert in accordance withthe present invention in an unassembled configuration.

[0011]FIG. 5 shows the formation of a first side tube.

[0012]FIG. 6 shows the formation of the second side tube.

[0013]FIG. 7 shows the formation of a first end tube.

[0014]FIG. 8 shows the formation of a second end tube.

[0015]FIG. 9 shows the reverse angle of FIG. 8.

[0016]FIG. 10 shows the formation of a first bottom tube.

[0017]FIG. 11 shows the formation of a second bottom tube.

DETAILED DESCRIPTION

[0018] The present invention relates to a packing insert for protectingan article. The following description is presented to enable one ofordinary skill in the art to make and use the invention and is providedin the context of a patent application and its requirements. Variousmodifications to the preferred embodiment and the generic principles andfeatures described herein will be readily apparent to those skilled inthe art. Thus, the present invention is not intended to be limited tothe embodiment shown but is to be accorded the widest scope consistentwith the principles and features described herein.

[0019] The preferred embodiment of the present invention is a corrugatedpacking insert for protecting a highly fragile component (i.e., harddisk drive) during shipment. Accordingly, the packing insert inaccordance with the present invention employs a low cost, environmentfriendly material (i.e. corrugated material) to protect fragilecomponents from any potential damage that can be caused during theshipping process.

[0020] Although the present invention has been described in terms ofpackaging a hard disk drive, one of ordinary skill in the art willreadily recognize that it might also be used to package other kinds offragile materials and components which need to be protected from anypotential damage that could be caused during the shipping process.

[0021] For a more detailed description of the present invention, refernow to the following discussion in conjunction with the accompanyingfigures. FIG. 2 is an exploded view of a packaging system in accordancewith the present invention. The system comprises a box 100, a packinginsert 200, and a top insert 400. The top insert 400 is placed above acomponent 300 after nesting the component 300 within the packing insert200. The packing insert 200, the component 300, and the top insert 400are then placed in the box 100.

[0022] Preferably, both the packing insert 200 and the top insert 400are compressive and shock-absorbent. Specifically, the packing insert200 and the top insert 400 are comprised of a compressive andshock-absorbent material. Further information about compressive andshock-absorbent properties in a packaging system is set forth inapplicant's U.S. patent application Ser. No. 09,981,186, filed Oct. 17,2001, and entitled PACKAGING SYSTEM FOR A COMPONENT INCLUDING ACOMPRESSIVE AND SHOCK-ABSORBENT PACKING INSERT, which is assigned to theassignee of the present application and is incorporated herein byreference. In the above-identified patent application, the packagingsystem includes the top insert 400 whereby the top insert 400 ispreferably made of a corrugated paper material due to the compressiveproperties of the material.

[0023] In a system and method in accordance with the presentapplication, the packing insert 200 is also preferably made of acorrugated paper material. Again, the corrugated paper material ispreferable due to the compressive properties of the material.Specifically, the corrugated paper material has a tendency to flex whenit is compressed during shock and vibration and therefore functions in amanner similar to that of a plastic foam typically utilized inconventional packaging systems. The corrugated paper material isconsiderably less expensive than the plastic foam and is alsobiodegradable and thus environment friendly.

[0024] Accordingly, the packing insert 200 is preferably utilized inconjunction with the top insert 400 to further enhance the compressiveand shock-absorbent properties of the packaging system. Additionally,since the corrugated paper material is considerably less expensive thanthe plastic foam, the cost of the packaging system in accordance withthe present invention is substantially lower than the cost ofconventional packaging systems.

[0025] Although the present invention has been described in terms ofbeing made of a corrugated material, one of ordinary skill in the artwill readily recognize that the present invention could be made with anyof a variety of low cost, environmentally friendly materials whileremaining within the spirit and scope of the present invention.

[0026] For a clearer perspective of the present invention, please refernow to FIG. 3. FIG. 3 shows an assembled packing insert 200 inaccordance with the present invention. Shown are a main panel 205, firstand second end tubes 210, 230, first and second side tubes 220, 240 anda first bottom tube 250. (A second bottom tube 260 opposite the firstbottom tube 250 is not shown.)

[0027] The first end tube 210 includes two slots 212, 213 and a cutout214. The first side tube 220 includes two cutouts 225, 226. The secondend tube 230 includes cutout 234 and an opening 235. The second sidetube 240 includes two cutouts 245, 246.

[0028] In designing the packing insert 200, much consideration is givento the placement of the various cutouts/slots/openings that are presentin the preferred embodiment of the packing insert 200. The placement ofcutouts/slots/openings in the corrugated material help enhance theflexing capability of the insert 200. Accordingly, the morecutouts/slots/openings that are 10 present on the insert 200, the moreflexible the insert 200 becomes. However, the lesscutouts/slots/openings that are present on the insert 200, the lessflexible (more rigid) the insert 200 becomes. Correspondingly, theabove-described placement of the cutouts/slots/openings on the packinginsert 200 in accordance with the present invention, represents apreferred configuration whereby a desired balance between flexibilityand rigidity is achieved.

[0029] Although the present invention has been described in terms ofspecific placements of cutouts/slots/openings in the packing insert, oneof ordinary skill in the art will readily recognize that thecutouts/slots/openings can be configured in a variety of different wayswhile remaining within the spirit and scope of the present invention.

[0030] For a detailed understanding of the packing insert in accordancewith the present invention, please refer now to FIG. 4. FIG. 4 is anillustration of the packing insert 200 in accordance with the presentinvention in an unassembled configuration. The insert 200 comprises themain panel 205 wherein the main panel 205 includes first and secondapertures 201, 203, the first and second apertures 201, 203 beinglocated on opposite sides of the main panel 205. The main panel 205further comprises first and second slots 202, 204, the first and secondslots 202, 204 being located on opposite sides of the main panel 205.

[0031] The insert 200 further comprises a first and second plurality ofend tube panels 210′, 230′ and a first and second plurality of side tubepanels 220′, 240′ wherein the first and second plurality of end tubepanels 210′, 230′ and the first and second plurality of side tube panels220′, 240′ are hingedly coupled to main panel 205. The first and secondplurality of end tube panels 210′, 230′ are respectively utilized toform the first and second end tube panels 210, 230 (see FIG. 3) and thefirst and second plurality of side tube panels 220′, 240′ arerespectively utilized to form the first and second side tube panels 220,240 (see FIG. 3).

[0032] The first plurality of end tube panels 210′ is adjacent to thefirst plurality of side tube panels 220′. The second plurality of endtube panels 230′ is adjacent to the first plurality of side tube panels220′ and opposite the first plurality of end tube panels 230′. Thesecond plurality of side tube panels 240′ is adjacent to the secondplurality of end tube panels 230′ and opposite the first plurality ofside tube panels 220′.

[0033] The first plurality of end tube panels 210′ includes a tab 211,two slots 212, 213, a cutout 214 and a push-in tab 215′. Similarly, thesecond plurality of end tube panels 230′ includes a tab 231, two slots232,233, a cutout 234 and a push-in tab 235′. The first plurality ofside tube panels 220′ includes a tab 221, three slots 222, 223, 224, andtwo cutouts 225, 226. Likewise, the second plurality of side tube panels240′ includes a tab 241, three slots 242, 243, 244, and two cutouts 245,246.

[0034] Again, it should be noted that the placement of thecutouts/slots/openings on the packing insert 200 in accordance with thepresent invention, represents a preferred configuration whereby adesired balance between flexibility and rigidity is achieved.

[0035] For an illustration of how to assemble the packing insert 200 inaccordance with the present invention, please refer now to FIGS. 5-11.To start, the first plurality of side tube panels 220′ are foldablyinserted into the first aperture 201 via the tab 221 thereby forming afirst side tube. Next, the second plurality of side tube panels 240′ arefoldably inserted into the second aperture 203 via the tab 241 therebyforming a second side tube.

[0036] For a further understanding, please refer now to FIGS. 5 and 6.FIG. 5 shows the formation of a first side tube 220. FIG. 6 shows theformation of the second side tube 240. Also shown in FIG. 5 are slots222, 224 and cutouts 225, 226 in the first side tube 220 and slots 242,244 and cutouts 245, 246 in the second side tube 240.

[0037] Next, the tab 211 of first plurality of end tube panels 210′ isfoldably inserted into the first slot 202 of the main panel 205 viaslots 224 and 244 of the first and second side tubes thereby forming afirst end tube. Next, the tab 231 of the second plurality of end tubepanels 230′ is foldably inserted into the second slot 204 of the mainpanel 205 via slots 222 and 242 of the first and second side tubesthereby forming a second end tube. Once the first and second end tubesare formed, push-in tabs 215′ and 235′ are pushed in to createrespective openings in the first and second end tubes.

[0038] For a further illustration, please refer now to FIGS. 7-9. FIG. 7shows the formation of a first end tube 210 and FIG. 8 shows theformation of the second end tube 230. Also shown in FIG. 8 are slots212, 213 and cutout 214 in the first end tube 210 as well as an opening235 in the second end tube 230, said opening 235 having been created viapush-in tabs 235′. FIG. 9 is the reverse angle of FIG. 8 and shows slots232, 233 and cutout 234 in the second end tube 230′ as well as anopening 215 in the first end tube 210, said opening 215 having beencreated via push-in tabs 215′.

[0039] Another feature associated with the present invention are bottomtubes located underneath the main panel 205. These are formed utilizingthe side tube panels. Accordingly, once the first plurality of side tubepanels 220′ are inserted into the first aperture 201, the tab 221 isinserted into the slot 223 whereby the tab 221 is locked underneath themain panel 205 thereby forming a first bottom tube. Similarly, tab 241of the second plurality of side tube panels 240′ is inserted into theslot 243 whereby the tab 241 is locked underneath the main panel 205thereby forming a second bottom tube.

[0040] For a further understanding, please refer to FIGS. 10 and 11.FIG. 10 is a bottom view of the insert and shows the formation of afirst bottom tube 250 whereby tab 221 is locked underneath the mainpanel 205. FIG. 11 is also a bottom view of the insert and shows theformation of a second bottom tube 260 whereby tab 241 is lockedunderneath the main panel 205.

[0041] The present invention is a corrugated packing insert forprotecting an article of manufacture (i.e. hard disk drive) duringshipment. Accordingly, the packing insert in accordance with the presentinvention employs a low cost, environment friendly material (i.e.corrugated material) to protect fragile components from any potentialdamage that can be caused during the shipping process.

[0042] Although the present invention has been described in accordancewith the embodiments shown, one of ordinary skill in the art willreadily recognize that there could be variations to the embodiments andthose variations would be within the spirit and scope of the presentinvention. Accordingly, many modifications may be made by one ofordinary skill in the art without departing from the spirit and scope ofthe appended claims.

What is claimed is:
 1. A packaging system for a component, the packagingsystem comprising: a box; and a compressible and shock-absorbent packinginsert, wherein the packing insert is placed in the box after nesting acomponent within the insert, the packing insert comprising: a mainpanel; a first end tube hingedly coupled to the main panel; a second endtube hingedly coupled to the main panel opposite the first end tube; afirst side tube hingedly coupled to the main panel, the first side tubebeing adjacent to the first end tube; and a second side tube hingedlycoupled to the main panel, the second side tube being adjacent to thesecond end tube and opposite the first side tube wherein the first andsecond side tube panels and the first and second side tube panelsinclude at least one cutout to enhance the flexing capability of thepacking insert.
 2. The packaging system of claim 1 wherein the packinginsert comprises a corrugated paper material that is biodegradable. 3.The packaging system of claim 2 wherein the first and second end tubeseach comprise a plurality of end tube panels wherein the plurality ofend tube panels each include a tab and a cutout.
 4. The packaging systemof claim 3 wherein the first and second side tubes each comprise aplurality of side tube panels wherein the plurality of side tube panelseach include a tab, at least one cutout, and a first, second and thirdslot.
 5. The packaging system of claim 4 wherein the main panel includesfirst and second apertures, the first and second apertures being locatedon opposite sides of the main panel.
 6. The packaging system of claim 5wherein the first side tube comprises first and second tube slots and atleast one cutout and the second side tube comprises first and secondtube slots and at least one cutout.
 7. The packaging system of claim 6wherein the insert further comprises: a first bottom tube locatedunderneath the main panel; and a second bottom tube located underneaththe main panel opposite the first bottom tube.
 8. The packaging systemof claim 7 wherein the main panel further includes first and secondslots, the first and second slots being located on opposite sides of themain panel.
 9. The packaging system of claim 8 wherein the first endtube comprises the cutout of the first plurality of end tube panels andthe second end tube comprises the cutout of the second plurality of endtube panels.
 10. A packing insert for protecting an article comprising:a main panel; a first end tube hingedly coupled to the main panel; asecond end tube hingedly coupled to the main panel opposite the firstend tube; a first side tube hingedly coupled to the main panel, thefirst side tube being adjacent to the first end tube; and a second sidetube hingedly coupled to the main panel, the second side tube beingadjacent to the second end tube and opposite the first side tube whereinthe first and second side tube panels and the first and second side tubepanels include at least one cutout to enhance the flexing capability ofthe packing insert.
 11. The packing insert of claim 10 wherein thepacking insert comprises a corrugated paper material that isbiodegradable.
 12. The packing insert of claim 11 wherein the first andsecond end tubes each comprise a plurality of end tube panels whereinthe plurality of end tube panels each include a tab and a cutout. 13.The packing insert of claim 12 wherein the first and second side tubeseach comprise a plurality of side tube panels wherein the plurality ofside tube panels each include a tab, at least one cutout, and a first,second and third slot.
 14. The packing insert of claim 13 wherein themain panel includes first and second apertures, the first and secondapertures being located on opposite sides of the main panel
 15. Thepacking insert of claim 14 wherein the first side tube comprises firstand second tube slots and at least one cutout and the second side tubecomprises first and second tube slots and at least one cutout.
 16. Thepacking insert of claim 15 wherein the insert further comprises: a firstbottom tube located underneath the main panel; and a second bottom tubelocated underneath the main panel opposite the first bottom tube. 17.The packing insert of claim 16 wherein the main panel further includesfirst and second slots, the first and second slots being located onopposite sides of the main panel.
 18. The packing insert of claim 17wherein the first end tube comprises the cutout of the first pluralityof end tube panels and the second end tube comprises the cutout of thesecond plurality of end tube panels.
 19. A packing insert for protectingan article comprising: a main panel, the main panel including first andsecond apertures, the first and second apertures being located onopposite sides of the main panel and first and second slots, the firstand second slots being located on opposite sides of the main panel; afirst end tube, the first end tube comprising a first plurality of endtube panels hingedly coupled to the main panel; a second end tube, thesecond end tube comprising a second plurality of end tube panelshingedly coupled to the main panel opposite the second end tube; a firstside tube, the first side tube comprising a first plurality of side tubepanels hingedly coupled to the main panel, the first side tube beingadjacent to the first end tube; and a second side tube, the second sidetube comprising a second plurality of side tube panels hingedly coupledto the main panel opposite the first side tube, the second side tubebeing adjacent to the second end tube wherein the first and second sidetubes and the first and second end tubes each include at least onecutout for enhancing the flexing capability of the packing insert. 20.The packing insert of claim 19 wherein the packing insert furthercomprises: a first bottom tube located underneath the main panel; and asecond bottom tube located underneath the main panel opposite the firstbottom tube.
 21. The packing insert of claim 20 wherein the first andsecond side tubes and the first and second end tubes each include atleast one cutout for enhancing the flexing capability of the packinginsert.
 22. The packing insert of claim 21 wherein the packing insertcomprises a corrugated paper material that is biodegradable.
 23. Apacking insert for protecting an article comprising: a main panel, themain panel including first and second apertures, the first and secondapertures being located on opposite sides of the main panel and firstand second slots, the first and second slots being located on oppositesides of the main panel; a first end tube, the first end tube comprisinga first plurality of end tube panels hingedly coupled to the main panel;a second end tube, the second end tube comprising a second plurality ofend tube panels hingedly coupled to the main panel opposite the secondend tube; a first side tube, the first side tube comprising a firstplurality of side tube panels hingedly coupled to the main panel, thefirst side tube being adjacent to the first end tube; a second sidetube, the second side tube comprising a second plurality of side tubepanels hingedly coupled to the main panel opposite the first side tube,the second side tube being adjacent to the second end tube wherein thefirst and second side tubes and the first and second end tubes eachinclude at least one cutout for enhancing the flexing capability of thepacking insert; a first bottom tube located underneath the main panel;and a second bottom tube located underneath the main panel opposite thefirst bottom tube.
 24. A corrugated packing insert for protecting anarticle comprising: a main panel, the main panel including first andsecond apertures, the first and second apertures being located onopposite sides of the main panel and first and second slots, the firstand second slots being located on opposite sides of the main panel; afirst end tube, the first end tube comprising a first plurality of endtube panels hingedly coupled to the main panel; a second end tube, thesecond end tube comprising a second plurality of end tube panelshingedly coupled to the main panel opposite the second end tube; a firstside tube, the first side tube comprising a first plurality of side tubepanels hingedly coupled to the main panel, the first side tube beingadjacent to the first end tube; a second side tube, the second side tubecomprising a second plurality of side tube panels hingedly coupled tothe main panel opposite the first side tube, the second side tube beingadjacent to the second end tube wherein the first and second side tubesand the first and second end tubes each include at least one cutout forenhancing the flexing capability of the packing insert; a first bottomtube located underneath the main panel; and a second bottom tube locatedunderneath the main panel opposite the first bottom tube.
 25. Apackaging system for a component, the packaging system comprising: abox; a compressible and shock-absorbent packing insert; and acompressible and shock-absorbent top insert, wherein the top insert isplaced above a component after nesting the component within thecompressible and shock-absorbent packing insert.
 26. The packagingsystem of claim 25 wherein the packing insert comprises: a main panel; afirst end tube hingedly coupled to the main panel; a second end tubehingedly coupled to the main panel opposite the first end tube; a firstside tube hingedly coupled to the main panel, the first side tube beingadjacent to the first end tube; and a second side tube hingedly coupledto the main panel, the second side tube being adjacent to the second endtube and opposite the first side tube wherein the first and second sidetube panels and the first and second side tube panels include at leastone cutout to enhance the flexing capability of the packing insert. 27.The packing system of claim 26 wherein the packing insert and the topinsert are comprised of a corrugated paper material that isbiodegradable.